Description:TECHNICAL FIELD
The current invention pertains to the Concrete
characteristics with x%, y% proportions of ferrochrome slag
(FC) and quarry dust (QD) to improve the slag gradation.
The use of ferrochrome slag- cement mixture as a cementitious
course to make flexible pavement-highway material is
investigated. The results indicate that the cement-treated
ferrochrome slag and quarry dust composites as viable
alternative pavement material.
BACKGROUND AND PRIOR ART OF THE INVENTION:
CN107445522A
The invention belongs to technical field of concrete
preparation, especially a kind of high-carbon chrome alloy
dreg concrete for hydroelectric project and preparation
method thereof, aggregate is used as by carbon ferrochrome
slag, and carry out rational compatibility with artificial
aggregate, regulation and control in conjunction with
technological parameter are prepared into concrete, compared
to the concrete using natural or manmade aggregate
preparation, reduce process costs, the recycling of resource
is realized, social benefit and environmental benefit are
notable.
CN114133176A
The invention provides ferrochromium slag sand concrete fine
aggregate which comprises
SiO240-45％、Al2O316-18％、Fe2O32-5％、CaO 2-5％、MgO
3
19-23％、SO30.15-0.25％、Na2O0.2-0.5％、K2O 0.2-0.5％、Cr2O35 to 9
percent. The invention also provides C30 concrete containing
the ferrochrome slag sand concrete fine aggregate, which
comprises 270g of cement, 200g of water, 100g of fly ash,
1000g of machine-made sand, 500g of ferrochrome slag sand and
900 g of broken stone. The invention provides a C50 concrete
containing ferrochromium slag sand concrete fine aggregate,
which is prepared from the following raw materials in parts
by weight: 400g of cement, 180g of water, 80-100g of fly ash,
400g of machine-made sand, 450g of ferrochrome slag sand and
1100g of gravel. The invention solves the problems that the
existing steel waste residue can not be recycled and pollutes
the environment. The invention uses the iron and steel waste
residue ferrochromium slag sand as concrete fine aggregate,
and the iron and steel waste residue ferrochromium slag sand
is used together with the traditional stoneCompared with the
limestone machine-made broken stone, the mechanical
properties such as compressive strength, elastic modulus and
the like can be obviously improved, and the method has
obvious economic benefit.
CN104030586A
The invention discloses a method for producing an
environment-friendly active cement composite material by
means of ferrochrome tailings. The method is characterized in
that the material is produced by mixing three percent to five
percent of ferrochrome powder, three percent to five percent
of clinker powder, three percent to five percent of dry
powder coal ash and three percent to five percent of exciting
agents. The method has the advantages that machining and
excitation modification are performed on the industrial waste
residue ferrochrome tailings, the tailings are doped into the
cement clinker, the method is simple and easy to operate, and
a positive promoting role in recycling the industrial solid
waste, improving the resource comprehensive utilization rate
and saving and reasonably and effectively utilizing the
resources are played. According to the obtained cement based
composite material, the concrete mechanical property can be
improved, the cement and concrete engineering cost is reduced,
the heat of hydration of the concrete is obviously reduced,
4
workability of the concrete is improved, segregation and
bleeding are reduced, temperature difference changes and
internal pressure of mass concrete are reduced, and cracks
caused by the temperature difference is restrained; alkali
aggregate reaction of the concrete can be effectively
restrained; the micro-aggregate effect is achieved.
CN108947348A
Concrete is reproduced using ferrochrome production waste
residue the invention discloses a kind of, comprising the
following steps: S1: after taking ferrochrome to produce
remaining waste residue crushing, crosses 1000 meshes；S2: the
waste residue after S1 step process is mixed with kaolin and
calcite according to mass ratio for 10:2:3,1000 DEG C of -
1300 DEG C of high-temperature calcinations are then carried
out；S3: crushing, and crosses 500 meshes, obtains waste
residue mixture；S4: it is stirred and is mixed to obtain the
final product according to following mass fraction proportion:
10 parts of waste residue mixtures, 5-8 parts of cement, 2-5
parts of quartz sands, 15-20 parts of stones, 1-3 parts of
fibers.The present invention is not only avoided that
pollution problem caused by ferrochrome waste sludge
discharge, also can improve concrete properties using waste
residue.
CN109251004A
It is the high-strength concrete and preparation method
thereof of main aggregate that the invention discloses a kind
of with carbon chromium slag, is related to technical field
of concrete；Described includes primary raw material carbon
chromium slag building material powder with the high-strength
concrete that carbon chromium slag is main aggregate, carbon
chromium slag building material powder content by percentage
to the quality are as follows: carbon chromium slag aggregate
60~80%, ferronickel slag 8~15%, light calcined magnesia
8.5~40%, magnesium chloride 1.7~12.9%, flyash 2~5%, defoaming
5
agent 0.05~0.5%, the additive amount ratio of composite
modified agent solution 0.15~2.6%, the carbon chromium slag
aggregate and the ferronickel slag is in mass are as follows:
5:1~7:1.The present invention prepares strong concrete using
carbon chromium slag, and added value is high, and
utilization is big, instead of being able to solve the
problem of carbon chromium slag is accumulated while
sandstone aggregate, has positive economic significance and
environment protection significance.
CN103073210A
The invention discloses a modified high carbon ferro-chrome
slag aggregate for road concrete and a preparation method of
the modified high carbon ferro-chrome slag aggregate. The
modified high carbon ferro-chrome slag aggregate is
characterized by being prepared from a high carbon ferrochrome
alloy slag aggregate and a chemical modifying agent
accounting for 2-6 percent of the mass of the high carbon
ferro-chrome alloy slag aggregate through mixing, wherein the
chemical modifying agent is prepared from 100 parts by mass
of polymer diluting solution, 0.5-1.2 parts by mass of
organic silicon waterproof defoaming agent, 0.2-0.5 part by
mass of polyvinyl alcohol and 2-4 parts by mass of zeolite
powder through uniform mixing; the polymer diluting solution
is prepared by diluting a polymer emulsion stock solution
through adding water; and the polymer emulsion stock solution
is any one of a butylbenzene emulsion, a polyacrylate
emulsion, a polyethylene-vinyl acetate emulsion and a
styrene-acrylic emulsion. By adopting the invention, waste
alloy waste is used as a raw material, and thus building
materials of carbon chromic slag can be recycled and
efficiently utilized, and the defects and the hidden dangers
of the carbon chromic slag as the concrete aggregate are
solved; and the preparation method is simple and easy to
realize and is strong in practicability.
6
JPH05262542A
To utilized ferroalloy slag as a concrete aggregate by mixing
the ferroalloy slag which is air-crushed into spherical
particles of less than prescribed size with sand at a
specific ratio. CONSTITUTION:Ferroalloy slag (for example,
ferrochromium slag) is air-crushed into spherical particles
of less than 5mm diameter is utilized as a concrete aggregate
by mixing with sand at a volume ratio of 7/3 to 4/6, or
further, with a combination of water-reducing admixture and
thickeners, to increase the concrete strength and maintain
high fluidity despite the reduced water volume. Thus, the
mold frames can be readily filled with the concrete by no use
of vibrators, resulting in increased initial strength.
CN109776042A
The invention discloses a kind of highway alloy dreg
concretes, according to water-cement ratio (W/B) 0.46, it is
made with 165 parts of water, 270 parts of cement, 90 parts
of flyash, 750 parts of slag sand (internal reference
mountain flour 8%), 1160 parts of Fe alloy slag rubbles, 3.5
parts of water-reducing agents and 0.02 part of waterretaining
agent is added in every 100 parts of
concrete.Concrete structure mechanical property produced by
the present invention is reliable, and workability is
preferable, convenient construction, can be used in the
construction of highway pavement, road shoulder.It is
experimentally verified that concrete seven d, 28d
compression strength is respectively 23.3MPa, 33.5MPa.It
replaces ordinary gravel as gathering materials using Fe
alloy slag, can not only largely consume industrial solid
castoff, while also can be reduced the dosage of natural sand
stone, save material, reduce the environmental pressure of
industrial residue discharge, social benefit is huge with
economic benefit.
7
RU2703036C1
invention relates to methods of producing concrete mixture
and heat-resistant concrete articles suitable for making
lining of industrial heat and refractory units, in particular
for lining firing bricks and other units. In the method of
producing heat-resistant concrete mixture, which includes
mixing chamotte filler and self-decomposing ferrochromium
slag, according to the invention, chamotte filler used is
chamotte flue dust in amount of – 11.1…12.2 %, selfdecomposing
ferrochrome slag in amount of 13.8…15.4 %,
additionally, the following is added: spent aluminum alloys
etching solution – 40.0…42.0 % and nickel slag in amount of
30.4…35.1 %, mixing is carried out in a reactor at pH 7.7…8.5
and T = 150…155 °C, then mixture is ground to particle size
4…7 mm in disintegrator. Besides, the technical result is
achieved due to that in the method of making articles from
heat-resistant concrete mixture containing self-decomposed
ferrochrome slag and chamotte filler, including its hardening,
according to invention, said concrete mixture is produced
according to said composition, compacted on vibrating bench,
and hardening is performed in hot treatment in hot air
chamber at temperature 150…155 °C for 6 hours and obtain
article with strength equal to and less than 85…90 MPa.
Proposed method makes it possible to efficiently use
production wastes that do not find wide industrial
application, improve environment, obtain strong heatresistant
concrete products.
EFFECT: improvement of environment ecology due to use for
production of concrete mixture of production wastes processed
with low power consumption, and production of heat-resistant
concrete products with high strength (at least 85…90 MPa).
8
CN111847944A
The invention belongs to the technical field of concrete
modification, and particularly relates to ferrochrome slag
for concrete aggregate and a preparation method thereof,
wherein the ferrochrome slag comprises the following
components in parts by weight: 80-95 parts of ferrochromium
slag, 5-10 parts of metakaolin and 8-15 parts of zeolite
powder, wherein the metakaolin and the zeolite powder form
composite powder and are attached to the surface of the
ferrochromium slag. The invention carries out technical
innovation from the viewpoint of inhibiting chromium
dissolution and solidifying dissolved chromium, so that the
ferrochrome slag can be applied to concrete and has
industrial value.
CN109761548A
The invention discloses a kind of Fe alloy slag aggregate
concretes, with reference to the match ratio of ordinary
gravel concrete, using L16 orthogonal test, using slump △ h,
divergence D, the time t that decays, 7 days intensity Rc as
control sample, pre-wetted treatment is carried out to Fe
alloy slag surface simultaneously, mountain flour and waterretaining
agent are participated in match ratio, the pump
concrete for replacing ordinary gravel to prepare with Fe
alloy slag rubble, sand is designed, can effectively solve
the defect that the working performance that conventional
concrete proportion occurs in the concrete being prepared is
poor, loss of slump is fast, workability is poor,
cohesiveness is low.System solves the problems such as Fe
alloy slag Concrete Pumping Construction is difficult,
concrete quality fluctuation is big, at high cost.Furthermore
the present invention replaces ordinary gravel as gathering
materials using Fe alloy slag, can not only protect
environment, while save the cost, be a kind of production
technology for being worth promoting in building trade.This
technique cannot be only used in pavement construction,
9
moreover it can be used in the construction of building
structure.
DETAILED DESCRIPTION
In the current circumstance, our natural resources are
depleting day by day, so we must devise new conservation
strategies. As part of this, a substantial amount of
industrial waste is used for road construction. The
investigation of cost-effective alternative materials for
road construction is urgently required.
As a result of global population growth, the rapid expansion
of industrialization, manufacturing, and production
activities, and the concomitant generation of byproducts, the
environmental burden is increasing.
Industrial byproducts not only consume the available land
area but also contaminate the existing environmental
conditions, posing significant obstacles to their safe
disposal.
To work towards sustainable measures for the safe handling
and disposal of byproducts.achieving the sustainable and
appropriate utilisation of industrial byproducts. Utilization
of industrial byproducts derived from a variety of
metallurgical processes to create sustainable innovations
[1]. From process sources, various slags can be obtained,
which must be pre-treated to remove any residual metal. These
slags are used for the production of cement and cement
blocks, as well as roadbed aggregate. Incorporating
industrial slag products, such as Ferrochrome slag, into the
existing composition of construction materials, with the goal
of achieving a cost-effective solution for both industry and
infrastructure units, is a remedial measure for the
sustainable and efficient utilisation of industrial slag
products. The extraction of pure ferrochromium from chromium
ore generates ferrochrome slag, which is an industrial solid
waste. Ferrochrome is an essential corrosion-resistant
element in stainless steel. Ferrochrome slag deposits for the
production of stainless steel are increasing at an alarming
rate. The majority of pavements consist of coarse aggregates,
which facilitate the transfer of loads through physical
10
interlocking. Every metallurgical slag aggregate with a high
specific gravity may contribute greater strength than
conventional aggregate, and with the proper technical support
and awareness of its use, dumping and environmental issues
can be minimised. In close proximity to Visakhapatnam are two
ferrochrome production facilities that generate slag deposits
covering hundreds of acres. This paper outlines the
comprehensive use of ferrochrome slag in road construction.
BRIEF DESCRIPTION OF DRAWINGS
The objects and features of the present invention, which are
believed to be novel, are set forth with particularity in the
appended claims. The present invention, both as to its
organization and manner of operation, together with further
objects and advantages, may best be understood by reference
to the following description, taken in connection with the
accompanying drawings, in which:
Figure 1. Image of Ferrochrome slag utilized for current
invention
Figure 2.Image Quarry dust utilized for current invention
Figure 3. Image depicting the Specimen failure condition
during testing stage
Figure 4. Photo of Polyethylene cover wrapped specimens as in
during the Moist curing process.
11
Figure 5. The plot representing the Gradation curve of
ferrochrome slag and quarry dust
Figure 6. The plot representing the Gradation curves of
FC70QD30 and FC60QD40
Figure 7. Unconfined compressive strength of mixtures of
FC70QD30
Figure 8. Unconfined compressive strength of mixtures of
FC70QD40
Further, skilled artisans will appreciate that elements in
the drawings are illustrated for simplicity and may not have
necessarily been drawn to scale. For example, the flow charts
illustrate the method in terms of the most prominent steps
involved to help to improve understanding of aspects of the
present invention. Furthermore, in terms of the construction
of the device, one or more components of the device may have
been represented in the drawings by conventional symbols, and
the drawings may show only those specific details that are
pertinent to understanding the embodiments of the present
invention so as not to obscure the drawings with details that
will be readily apparent to those of ordinary skill in the
art having the benefit of the description herein.
12
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
To promote an understanding of the principles of the
invention, reference will now be made to the embodiment
illustrated in the drawings, and specific language will be
used to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended, such alterations and further modifications in the
illustrated system, and such further applications of the
principles of the invention as illustrated therein being
contemplated as would normally occur to one skilled in the
art to which the invention relates. It will be understood by
those skilled in the art that the foregoing general
description and the following detailed description are
exemplary and explanatory of the invention and are not
intended to be restrictive thereof.
Reference throughout this specification to "an aspect",
"another aspect," or similar language means that a particular
feature, structure, or characteristic described in connection
with the embodiment is included in at least one embodiment of
the present invention. Thus, appearances of the phrase "in an
embodiment", "in another embodiment" and similar language
throughout this specification may, but do not necessarily,
all refer to the same embodiment.
13
Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by
one of ordinary skill in the art to which this invention
belongs. The system, methods, and examples provided herein
are illustrative only and not intended to be limiting.
To classify ferrochrome slag as a material for highway
pavement.
Evaluating the compatibility of gradation from various
combinations of ferrochrome slag and quarry dust in flexible
pavement in accordance with the MoRTH Vth revision.
Analyzing the performance characteristics of combinations of
ferrochrome slag and quarry dust using the California Bearing
Ratio (CBR)
The materials consist of ferrochrome slag (10 mm - 1.18 mm)
and quarry dust (4.75 mm). Coarse aggregate is a significant
component of pavements' load-bearing capacity. Therefore,
their properties must be evaluated prior to their use in
pavement construction. They must be the proper size and shape
for the pavement to behave as a single unit. In accordance
with IS: 2386, paving materials are typically evaluated for
shape, hardness and toughness, and water absorption. The
Jindal Stainless Steel Industry in Kothavalsa, Vizianagaram,
Andhra Pradesh collects ferrochrome slag. Vizianagaram
district quarry dust is obtained from a nearby quarry in
Sompuram.
Characterization of Ferrochrome Slag
14
Physical and mechanical properties of the aggregate
ferrochrome slag Conforming to IS: 2386 Part III-1963, water
absorption and specific gravity tests are conducted.
The shape tests are carried out in accordance with IS: 2386
Part I-1963. The tests for crushing value, impact value, and
abrasion value are conducted in accordance with IS: 2386 Part
IV-1963.
Soundness test
The aggregate size (10mm to 4.75mm) is examined for soundness
using anhydrous magnesium sulphate.
In order to dissolve the anhydrous salt crystals, the
saturated solution of anhydrous magnesium sulphate is
prepared according to the code (IS: 2386 Part V-1963) and
stored for 48 hours prior to the test. Ferrochrome slag is
submerged in a solution for 16 to 18 hours and heated to a
constant weight at 1100 degrees Celsius. Immersion and
heating are repeated a total of 10 times. After the last
cycle, the slag is washed with BaCl2 to eliminate salt
patches and then weighed. After ten cycles, the average
weight loss of aggregates to be used in the construction of a
pavement should be less than 18% when magnesium sulphate
solution is used.
Particle size distribution
Conforming to IS: 2386 Part IV-1983, the particle size
distribution is measured. Ferrochrome slag Contains 62.43
15
percent gravel and 37.57 percent sand, with no fines. The
coefficient of homogeneity (Cu) equals 3, while the
coefficient of curvature (Cc) equals 1.33. The dust consists
of 0.5% gravel and 90.5% sand and 9% of the finer material.
Both ferrochrome slag and quarry dust are low-quality
substances.
Compaction characteristics
The Modified Proctor Test/Heavy Compaction Test is conducted
in accordance with IS: 2720 part VIII-1983 to determine the
highest dry density and optimal moisture content. Due to the
minute amount of fines, ferrochrome slag is impervious to
moisture. Therefore, it is impossible to perform compaction.
Maximum Dry Density and Ideal Moisture Content of Quarry Dust
are 2.047 g/cc and 10.36%, respectively.
California bearing ratio test
The California Bearing Ratio (CBR) is the resistance of
flexible pavement material to penetration. The test is
performed on remoulded pavement material at Maximum Dry
Density (MDD) and Optimum Moisture Content (OMC). According
to IS: 2720 part XVI-1987, three specimens are prepared for
each sample at MDD, and OMC must be soaked for 96 hours in
order to conduct the CBR test. The average CBR of Quarry Dust
is 24.3 percent.
16
Compatibility with different combinations of ferrochrome slag
and quarry dust in accordance with the MoRTH specification
The invention details, ferrochrome slag is restricted to a 10
mm particle size, which is also water-resistant without
fines. In the absence of a fine component, it is necessary to
investigate alternative fine materials and combine them with
ferrochrome slag in various proportions to achieve the
desired gradation. Therefore, ferrochrome slag is
mechanically stabilised with quarry dust in the following
proportions: 90/10, 80/20, 70/30, 60/40, and 50/50. According
to IRC: SP: 89 (Part I) -2010, the fundamental principles of
stabilisation are proportioning and compaction. To achieve
the desired gradation, a granular material with negligible
fines can be proportioned with a finer material. Industrial,
constructional, and Demolition Wastes must meet the gradation
requirements for cement-treated Sub-base and Base layer
material outlined in Table 3 of IRC: SP: 89 (Part II) -2018.
Consequently, mixtures of ferrochrome slag and quarry dust
must meet the required gradation for use as sub-base and base
materials in flexible pavement.
Gradation analysis
In accordance with IRC: SP: 37 (Part II) -2018, Ferrochrome
slag and Quarry dust are mixed in various proportions up to
50 percent to meet the required gradation. The materials used
17
for cement stabilisation must have a coefficient of
uniformity (Cu) of at least 5 and be graded properly. The
FC70QD30 and FC60QD40 mixes are well graded with a
coefficient of uniformity (Cu) greater than 5, meeting all
the specifications for cement-treated bases and sub-bases.
FC80QD20 and FC50QD50 have met the required grade but are
poorly graded, whereas FC90QD10 has not met the required
grade.
Engineering properties of Ferrochrome slag, Dust and their
combinations
The engineering properties of ferrochrome slag can be
enhanced by adding Quarry Dust in varying proportions. On the
basis of the mixtures' gradation suitability, the Modified
Proctor Test and the California Bearing Ratio Test are
conducted.
Compaction characteristics
Mixtures are subjected to a modified proctor test in
accordance with the standard procedure. Considering the
maximum utility of ferrochrome slag, 30% to 40% of quarry
dust is combined with ferrochrome slag. The MDD of the
mixtures is 2.392 and 2.368 g/cc, respectively. The OMC of
the mixtures is 6,17% and 6,44%, respectively. Mix FS70QD30
has a high density due to the ferrochrome slag's greater
specific gravity, while Mix FS60QD40 has a high OMC because
it contains more quarry dust.
18
California Bearing Ratio
CBR is performed in accordance with standard procedure to
evaluate the stability of both mixtures. For the test, three
specimens are prepared at MDD and OMC. The observed average
CBR values for mixtures are 74.44% and 65.6%. Mix FS70QD30
has a higher CBR value than FS60QD40, as a result of its
higher MDD. , Claims:5. CLAIMS
The claims defining the invention are as follows:
1. the ferrochrome slag's physical and mechanical
characteristics fall within the parameters of the
specification and allow for a more affordable substitute
for traditional aggregates in the sub-base and base
courses of flexible pavements.
2. The flexible pavement as stated in claim 1, The
ferrochrome slag (FC) soundness test is 2.83% which is
within acceptable limits, and no observable cracks when
inspected individual particles.
3. As in claim 1, the blending of ferrochrome slag (FC) and
quarry dust (QD) are in proportions of 90/10, 80/20,
70/30, 60/40, and 50/50 are all evaluated to improve the
slag gradation and find the optimal ratio.
4. Due to a lack of fines in the ferrochrome slag (FC)
gradation, quarry dust (QD) was used for mechanical
stabilisation in accordance with IRC: SP: 89 (Part I)-
2010.
5. In flexible pavement, mixtures of FC70QD30 and FC60QD40
have produced the necessary gradation of cement bound
granular layers.
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6. The proposed grades FC70QD30 and FC60QD40 have CBR values
of 74.44% and 65.69%, respectively, and are more stable
due to the high interlocking properties of the ferrochrome
slag with quarry dust.